DC System

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TATA CONSULTING ENGINEERS TCE.M6-EL-7186000

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DC SYSTEM

DESIGN GUIDE FOR DC SYSTEM

TATA CONSULTING ENGINEERS 73/1, ST. MARK’S ROAD BANGALORE 560 001

FLOPPY NO FILE NAME

: TCE.M6-EL-FP-DOC-006 : M6-6000.DWG

REV.NO

R1

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R3

ISSUE

INITIALS

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INITIALS

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DATE

92-09-04

97-03-31

INITIALS

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99-03-02 FORM NO. 020R2

TATA CONSULTING ENGINEERS TCE.M6-EL-7186000

SECTION: REV. STATUS

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DC SYSTEM

REVISION STATUS REV. NO

DATE

R3

99-03-02

DESCRIPTION

1.Design guides for Lead Acid battery-(M6-EL-BT-6000 R2),NiCad battery (M6-EL-BT-6000A R1) and battery Chargers(M6-EL-BC-6004 R2) have been combined to make a composite design guide on the ‘DC System’. 2. In addition the loads considered for emergency lighting , auxiliary relays and indicating lamps have been revised. 3.Section 4.0 providing recommendation for quantities of batteries in different installations has been revised.

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DC SYSTEM

CONTENTS PART-A LEAD ACID BATTERY SL.NO. 1.0

TITLE SCOPE

SHEET NO. 2

2.0

TYPES OF LEAD ACID CELLS

2

3.0

SELECTION OF DC VOLTAGE LEVELS

3

4.0

QUANTITIES OF BATTERIES

5

5.0

AMPERE HOUR CAPACITY SIZING

6

6.0

INSTALLATION OF BATTERY

11

7.0

REFERENCES

13

APPENDIX-1 TYPICAL EMERGENCY LOADS

14

APPENDIX-2 RATING AND DESIGNATION

16

CAPACITIES AND DIMENSIONS OF TUBULAR CELLS

18

CAPACITIES AND FINAL CELL VOLTAGE OF HDP TUBULAR CELLS AT VARIOUS RATES OF DISCHARGE AT 27deg.C

19

CAPACITIES AT 27deg.C AT VARIOUS RATES OF DISCHARGE OF TYPE II HDP CELLS (TUBULAR)

20

PERFORMANCE CURVES TYPE-II HDP CELLS (TUBULAR)

21

CAPACITIES AND DIMENSIONS OF PLANTE CELLS

23

APPENDIX-3 BATTERY SIZING - SAMPLE CALCULATION

24

APPENDIX-4 TYPICAL BATTERY ROOM PLAN

31

SAMPLE WORK SHEET

32

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DC SYSTEM

CONTENTS PART-B NICAD BATTERY SL.NO. 1.0

TITLE SCOPE

2.0

DIFFERENT TYPES OF NICAD CELLS

35

3.0

PERFORMANCE CHARECTERISTICS

35

4.0

APPLICATIONS OF NICAD BATTERIES

38

5.0

MODE OF OPERATION

39

6.0

NUMBER OF CELLS

40

7.0

OTHER CONSIDERATIONS FOR SIZING NICAD BATTERIES

41

8.0

INSTALLATION

42

9.0

BATTERY SIZING CALCULATIONS

43

10.0

SPECIFYING THE BATTERY

44

11.0

REFERENCES

45

APPENDIX-1 CELL DESIGNATION

SHEET NO. 35

46

PREFERRED DIMENSIONS

47

DISCHARGE DATA FOR NICAD BATTERY (L,M & H TYPE CELLS)

48

TEMPERATURE CORRECTION FACTOR CURVES APPENDIX-2 SAMPLE CELL SIZING CALCULATION CELL SIZING WORK SHEET

64 67 69

APPENDIX-3 COMPARISION OF NICAD BATTERIES WITH LEAD ACID BATTERIES

71

SAMPLE WORK SHEET

72

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CONTENTS PART-C BATTERY CHARGER SL.NO.

TITLE

SHEET NO.

1.0

SCOPE

75

2.0

RECOMMENDED PRACTICE

75

3.0

DISCUSSION

79

4.0

ENCLOSURES i) FLOAT CUM BOOST CHARGER WITH 2 x 100% BATTERIES ii)

iii)

TCE.M2-EL-CW-S-2631 R0

FLOAT CUM BOOST CHARGER WITH 1 x 100% BATTERY

TCE.M2-EL-CW-S-2632 R0

FLOAT AND BOOST CHARGER WITH 1 x 100% BATTERY

TCE.M2-EL-CW-S-2633 R0

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PART – A : LEAD ACID BATTERY

PART-A LEAD ACID BATTERY

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PART – A : LEAD ACID BATTERY

1.0

SCOPE This design guide outlines the recommendation for the determination of voltage level, capacity, quantities and installation of DC battery of lead acid storage type required for providing DC power supply to essential services in the plant when the normal power supply fails. This also gives consideration to the safe shut down of the plant as well as human safety.

1.1

This section (Part –A) of this guide pertains to lead acid batteries and also includes a few recommendations applicable to NiCad batteries also like selecting voltage levels. The sizing criteria for Nickel Cadmium batteries are dealt in Part – B of this design guide and Part – C of this guide covers details about Battery chargers .

2.0

VARIOUS TYPES OF LEAD ACID CELLS

2.1

The plante type cells are more rugged, need less maintenance and have a life expectancy of about 15-18 years, which is 5-7 years longer than that for tubular type. However, the plante type battery is costlier than the tubular type. All the manufacturers make tubular cells while very few manufacturers make plante cell.

2.2

The cells with tubular plate construction are smaller in size than the plante type for a given AH rating.

2.3

The following types of tubular cells are available in the market in addition to standard variety : a) b) c)

High Discharge Performance (HDP) Maintenance Free-Valve Regulated (MF-VR) Low-Maintenance (LM) type

2.4

The capacity of HDP cells under short duration discharge conditions are higher than that of normal tubular batteries and are comparable to that of Plante type batteries. Hence the capacity of battery required will be smaller than that with the standard performance cells for applications requiring high discharge currents for short duration. Hence these cells are preferred for power plant applications.

2.5

The MF-VR cells require minimal attention from operation / maintenance staff and are stated to need no topping up of distilled water and no regular equalising charges. This type is well suited in ISSUE R3 FORM NO. 120 R1

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the plants where organised maintenance is infrequent. The low maintenance cells have grids made of low-antimony lead and require topping up only once in a year or so even at higher float voltages like 2.25 VpC. Hence this type also is well suited for plants where organised maintenance is infrequent or standalone substations in the distribution system or medium or small scale industries or where battery capacity is less than 300/500 AH. 2.6

The operating experience of the MF-VR and LM type cells for large capacities is limited and very few manufacturers make the same. Hence the sizing of these cells is not being discussed in the present guide and use of these cells may be decided on case to case basis.

2.7

The recommended float voltage for lead acid batteries is between 2.16 V and 2.25V/ cell. The recommended boost charging duration is 10 hours in case of smaller capacity batteries and 14 to 16 hours for larger capacities (1000 AH and above). The recommended maximum boost charger voltage is 2.75 V/cell. The recommended equalising charge voltage is 2.33 VpC.

3.0

SELECTION OF DC VOLTAGE LEVELS

3.1

The voltage level selection for the plant shall consider the following aspects :

3.2

a)

Quantum of power

b)

Individual load point power ratings, quantum of such load points and the geographic spread of the load points

c)

Standard voltages suitable for the equipment

For the same power requirement, the battery room size, and battery cost with higher voltage will be higher than those with lower voltage. However, the lower voltage requires higher current for the loads and hence to meet this current and to limit the voltage drop within limits cable sizes will be higher than those with higher voltage. Considering all the aspects following voltage levels are recommended.

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3.2.1 Power Plant 3.2.1.1 Large power plants (Coal based) a)

For electrical power, control & protection requirements

-

b)

I&C system

Normally most of the I&C vendors' systems are suitable for +24V or 48V DC.The voltage level shall be fixed after I&C system requirement is finalised.

c)

Isolated auxiliary plants

-

30 V DC or 110 V DC like raw water pump house (dedicated battery if running lengths of cables from the main plant is comparatively much higher)

d)

Switchyards

-

220 V DC (If switchyard has got separate control building)

e)

Coal handling plant

-

110 V DC/220 V DC

3.2.1.2 Gas based/diesel/Hydro

-

110 V/220 V DC power plants including captive power plants

3.2.2

220 V DC

Industrial Plants a)

Large plants with many load points and distributed in large area

220 V DC

b)

Small plants with multiple load points and outdoor substations

110 V DC

c)

Small plants with very few switchboards / load points

30 V DC

d)

For process control

Generally 24/48V (As required by the I&C system design)

-

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4.0 4.1 4.1.1

4.1.2

QUANTITIES OF BATTERIES Power Plants a) In case of unit sizes upto 250 MW, each unit shall be provided with one battery and also, a separate battery shall be provided for the common services of these units and switchyard load. The unit and common services batteries shall be sized to cater one unit and station service loads so that one serves as a standby to the other. b)

For instrumentation and control system two 100% batteries for each unit shall be provided.

c)

If switchyard is having a separate control building one 100% battery shall be provided for the switchyard. In addition switchyard DCDB will be provided with a tie feeder from station DCDB (as a standby).

d)

One no. 100% rating battery shall be considered for coal handling plant DC power requirements.

For large power units (500 MW and above) and nuclear power plants, for each unit, the 220V DC unit loads shall be divided into two categories, e.g. a)

D.C. power loads comprising D.C. motor drives, solenoids, emergency lighting , etc.

b)

D.C. control loads comprising tripping and closing circuits, indicating lamps, protection and control panels, safetysupervisory systems etc.

Each category of loads will be catered to by a separate 220V battery and battery charger system. There will be three 50% rated batteries.Each battery is capable of catering to 50 % power loads of unit ( since the power load requirement of 500MW unit is very huge ) and entire control load of unit. Normally two of the three batteries will cater power loads and the third one will be catering control loads. For switchyard load there will be a seperate 100% battery feeding switchyard loads.It is recommended to provide a tie from DCDB of control loads to DCDB of switchyard. One number 100% battery shall be considered for coal handling plant DC power requirement.

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4.1.3

Gas Power Plants The battery and charging equipment for each gas turbine is supplied by gas turbine supplier as part of the package.It is recommended to have each unit battrery rated to cater two gas turbine units.and a tie feeder is provided between one unit DCDB to another unit DCDB. The station and STG DC loads shall be catered by provision of 2X100% batteries . If switchyard and station building is seperate from the main plant control building a seperate 1X 100% dedicated battery shall be recommended. For catering I&C loads , it is recommended to have 2X 100% rated batteries for each unit.

4.1.4

Separate batteries with chargers are required to be provided for UPS for power plants. For details please refer to design guide M6-CL-AUG-715-6011 for UPS.

4.2

Industrial Plants and Small Power Plants Two 1X 100% rated batteries to cater for all the emergency power, control and protection requirements of the plant. Shall be provided. However, it shall be firmed up based on the quantum of the load points and their geographic location. A separate battery may be required for instrumentation, control and annunciation requirement for process purposes. The specific requirements in each case shall be ascertained. Separate batteries with chargers are required to be provided for UPS for Industrial and Small power plants. Possibility of using the same station battery for UPS as well may be explored on a case to case basis.

4.3

The recommendations on quantities are included int Part – C of this design guide in Tabular form.

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5.0

AMPERE HOUR CAPACITY SIZING

5.1

The capacity of a cell or battery as defined in Indian standards 1651 & 1652 is expressed in Ah, at 27deg.C, attainable when the cell or battery is discharged at the 10-hour rate to an end voltage of 1.85 V per cell. The capacity is a function of number of positive plates per cell.

5.2

The battery capacity is influenced by the factors listed below. a) b) c) d) e)

5.2.1

Duty cycle End of the duty cycle voltage Temperature correction factor Compensation for ageing Design margin

Duty cycle a)

At the time of power supply failure, the battery is required to supply D.C. power requirements of essential circuits for safe shut down of the station, vital instrumentation, controls, communication system, DC annunciation and emergency lighting.

b)

In power plants and some industrial plants an emergency diesel generator is available, which will provide a.c. power to the battery charger after the period required to start and connect it to the emergency AC bus. However, the battery size shall be calculated on the assumption that the engine driven generator may fail to start or operate satisfactorily.

c)

The duration for which each type of D.C. load will have to be supplied by battery when the normal power supply fails is different. The same may be continuous or for short time duration or momentary. In a typical power plant the DC power, control & protection loads and their classification based on duration for which they need to be supplied are as follows. Time duration i)

Upto 1 minute

Loads (Amperes) *

Trip relay / Trip coil currents of circuit breakers.

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*

Starting currents of all automatically started D.C. motors.

*

DC motor operated emergency steam stop valves.

*

Solenoid valves for isolation, safety relief, minimum recirculation etc.

*

Inrush currents of supervisory safety system for fuel, turbine and generator controls.

ii)

Upto one(1) hour

* * *

Emergency oil pump Jacking oil pump Steam generator control panels (including FSSS, Mill panels)

iii)

Upto two(2) hours

* * * * *

D.C. seal oil pump Scanner air fan D.C. emergency lighting P.A. system Annunciation (20%)

iv)

Upto 10 hours

*

* * •

d)

Indicating lamps / Semaphore indicators in switchgears/control panels Control room emergency lighting Annunciation (10%) Auxiliary relay ( which are likely to be energized during black out condition )

A table of loads indicating their power requirement and duration shall be prepared and a load curve for the battery shall be established. Appendix-1 indicates a table for typical emergency DC loads. Appendix-3 indicates a list of equipment and their typical D.C. loads for a 210 MW unit. It is recommended that project specific loads for DC motors, T.G. & S.G. vendor loads and inrush currents shall be obtained before proceeding with the sizing.

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e)

5.2.2

I&C battery for power plant application shall be sized to cater the loads for half hour. The loads to be considered shall be the maximum load of I&C system at any operating condition viz starting, running and tripping/stopping.

End of duty cycle voltage a)

The allowable end of duty cycle voltage of a battery has a major role in determination of the capacity of the battery. This in turn is dependent on the limits of system voltages that can be withstood by D.C. equipment. The D.C. equipment are generally rated to operate between +10% and -15% of their rated value with certain exceptions like trip coils and trip relays which can accept lower voltages.

b)

Manufacturers recommend a float voltage ranging from 2.06V to 2.3 volts per cell, for different float voltage adopted, the required frequency of equalising charges are given below. -----------------------------------------------------------------------------------Float Voltage Per Cell Approximate periodicity of equalising charges ----------------------------------------------------------------------------------2.25 No equalising charges 2.20 12 months 2.15 3 months 2.10 1 month 2.06 2 weeks ---------------------------------------------------------------------------------

c)

It is desirable to keep the float voltages as high as the D.C. system can accept to minimise frequency of equalising charges. It is recommended to keep a float voltage of 2.2V per cell. However, this shall be confirmed from the battery supplier specific to the project. i)

ii)

Considering the above, the number cells of a battery are selected as : Max.allowable DC voltage - Regulation due to charger --------------------------------------------------------------Float voltage per cell The end of duty cycle cell voltage is determined ISSUE R3 FORM NO. 120 R1

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by Min. allowable D.C. voltage + Cable drop ------------------------------------------------No. of cells d) Sl. No 1

2

Typical values for 220V DC system and 24V DC systems are given in the table below: System Max.allow Min.allowable No.of End of duty cycle voltage cells voltage able voltage 220V 242V 187V 108 1 min - 1.75V / cell 1,2 HRS & 10 hours 1.85V/cell 24V 30V* 21.5V* 13 1.8V/cell

* To be ascertained on project to project basis Note : For 110V & 30V plant DC systems, the details can be worked out in the same manner as for 220V system above.

5.2.3

e)

The cable drop to be considered in DC system shall be 2% from the charger/battery to Distribution board and 3% from board to any feeder in case of 220V DC system.

f)

In case of 24V DC system to keep the voltage drop within 5% limit, the cable sizes between DC board and I&C cabinets are very large and sometimes impractical to terminate. Hence for 24V system a total drop of 7.5% (2.5% between board and charger/battery and 5% between board and individual loads) is recommended.

Temperature correction factor The standard temperature for stating cell capacity is 27deg.C. If the lowest expected electrolyte temperature is below 27deg.C, a cell large enough to have the required capacity available at the lowest expected temperature shall be selected. The lowest electrolyte temperature shall be considered as 10o above minimum ambient temperature. If the lowest expected temperature is above 27deg.C, no correction factor shall be applied. The correction factor shall be calculated according to the formula: ISSUE R3 FORM NO. 120 R1

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Correction factor = / K \ for the lowest | 1 + -------- (27-T) | expected electrolyte | 100 | temperature, Tdeg.C \ / The factor 'K' for plante cells is 0.9 and for tubular, 0.43. The minimum electrolyte temperature (T) shall be considered as 10deg.C higher than the minimum ambient air temperature at site. 5.2.4

Compensation for age ANSI/IEEE STG.450-1270 recommends that a battery be replaced when its actual capacity drops to 80% of its rated capacity. Hence a factor of 1.25 shall be considered for ageing.

5.2.5

Design margin When the D.C. loads are more or less final at the time of battery sizing for tender specification purposes and/or the battery sizing is being done for a similar plant already executed, no design margin is considered necessary. If the sizing is being done for a new type of project or with very little confirmed loads, a design margin of 10 to 15% shall be provided over the final capacity arrived. While sizing the battery for nuclear power plant applications, it shall be noted that the "margins" required by IEEE STD.323-1273. 6.3.15 & 6.3.3 are to be applied during "Qualification" and are not related to "design margin".

5.3

Calculation of Ampere Hour Capacity The plante and tubular high discharge performance cells have better capacity factors at the short duration discharges (1 hour, 2 hours etc.). For durations less than one hour, the above types of cells have higher capacity factor than the tubular standard discharge performance cell. Hence for power plant application and for applications where short duration loads are appreciable high discharge performance cell shall be used. The capacity of the battery shall then be determined in accordance with the procedure outlined in Appendix-3.

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6.0

INSTALLATION

6.1

Battery cells shall be installed in a separate battery room, preferably near the D.C.load. The 24V batteries shall be in the same floor as I&C cabinets and as near as possible. Fig.4 included in design guide TCE.M6-EL-PJ-G-SG-6602 R1 (GA of Turbine Building Electrical Equipment & Space Organisation) indicates a typical battery Room Plan (Copy of Fig.4 enclosed as Appendix-4 for ready reference).

6.2

The flooring shall be provided with acid resistance tiles, a dished floor drain and drainage piping for collecting spilled acid. The spilled acid shall be diluted before discharging to the outside storm water drainage system.

6.3

Acid proof paint shall be provided on walls upto 2.3m height.

6.4

A wash basin shall be provided for emergency drenching of face and body.

6.5

The total capacity of exhaust fans (suitably distributed) should be minimum 1/10th of the total volume of the battery room per minute. The exhaust shall be directly outside the building. However, specific requirements shall be obtained from the battery manufacturer.

6.6

Separate cable(s) shall be provided for each polarity of the outgoing battery leads. If the cables are unarmoured they shall be taken in separate conduits and the conduits shall be PVC coated for protection against corrosion. Routing of any cables in cable-trays through battery room shall be avoided.

6.7

Adequate provision for storage of acid, distilled water, instruments, accessories, etc. should be provided in the battery room.

6.8

During float or boost charging of the lead acid battery hydrogen gas is generated. The volume of hydrogen gas generated depends on the amount of charging current. Also, the float current demand of a fully charged battery will double approximately for every 10deg.C rise above the base temperature of 27deg.C. Each fully charged cell produces 4.5 x 10-4 Cu.m (0.016 Cu.pt) hydrogen gas per hour per charging amperes in an ambient of 25deg.C to 27deg.C. Hydrogen explosive concentration is reached if the explosives mixture is three percent of the volume of room air.

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6.9

In view of the presence of hydrogen gas, warning signs shall be installed outside and inside the room prohibiting smoking, sparks of flame.

6.10

Lighting fixtures shall be vapour-proof type with reflectors painted with anticorrosive epoxy-paint. Lighting switch should be outside the battery room.

7.0

REFERENCES

7.1

IS:1651-1991

:

Stationary cells and batteries,lead-acid type with Tubular positive plates Specification.

7.2

IS:1652-1991

:

Stationary cells and batteries, lead-acid type with Plante' positive plates Specification.

7.3

IEEE Std 485-1273 :

Recommended practice for sizing large lead acid storage batteries for Generating Stations and Sub-stations.

7.4

IS:8320-1272

:

General requirements and methods of tests for lead-acid storage batteries

7.5

IS:1885-1965

:

Electrotechnical vocabulary Secondary cells and batteries.

7.6

IEEE Std. 450-1270 :

Recommended practice for maintenance testing and replacement of large lead storage batteries for generating stations and sub-stations.

7.7

IEEE Std. 484-1271 :

Recommended practice for Installation design and installation of large lead storage batteries for generating stations and substations.

7.8

IEEE Std. 323-1273 :

IEEE Standard for Qualifying class-1E Equipment for Nuclear Power Generating Stations.

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APPENDIX-1 TYPICAL EMERGENCY LOADS

1

a) Bearing oil pump b) Bearing oil pump for BFPT c) Bearing oil pump for MBFP

STEAM TG 500MW 120MW 13kW 15kW 2x5.5kW --11kW ---

2

a) Seal oil pump b) Seal water pump for BFPS

13kW 60kW

10kW ---

11kW ---

3

Jacking oil pump

35kW

37KW

28KW

4

Scanner air fan

----

4.4KW

7.5KW

5

Inverter for instruments

5kW

10kW

6

Inverter for PA system

2kW

2kW

2kW

7

Carrier panels



9

Auxiliary contactor (each)



10

DC emergency lights



11

UPS load (Incl. DAS, transmitters, controllers)

55kVA

45KVA

30kVA

210MW 13kW -----

.

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APPENDIX-1 (Cont’d) TYPICAL EMERGENCY LOADS

500MW

STEAM TG 120MW 210MW

1

Continuous Loads Annunciator window (each)

2

Indicating lamp (each)

ß -----5-10W For filament type ----à ß ----1 W For cluster LED type type ---à

3

Auxiliary relays (each)